MOTOR VEHICLE WIRE CONNECTOR.

Abstract

A high-current cable connector comprising two metal parts and a locking member. The locking member moves the metal parts outward so that two bearing surfaces on each metal part are pressed together. The alignment of the bearing surfaces causes two other surfaces on each metal part, the contact surfaces, to also be pressed together, locking the cable connector. This results in a cable connector that is easy to assemble and has low contact resistance and high thermal capacity.

Description

The subject matter relates to a motor vehicle cable connector and a method for manufacturing a cable connector. BACKGROUND OF THE INVENTION As the automotive industry becomes increasingly electrified, vehicles are transmitting ever-higher currents, typically via electrical cables. To enable connections between components such as power electronics, batteries, motors, etc., and cables, as well as connections between one cable and another, cable connectors are used. The so-called plug connectors are widely used. The most common connectors in the automotive sector are primarily based on spring contacts. In such spring-loaded connectors, a first and a second current-carrying base body, usually made of metal, are connected / held together by a spring positioned between them. The spring's restoring force allows for permanent mechanical and electrical contact between the spring element and the two base bodies. These springs, which are often very thin, are designed with numerous raised points on at least one contact surface adjacent to a base body, where the mechanical and electrical connection is established. Electrical current flows between the spring and the base body at these contact points. Due to the limited area of ​​this raised surface, the contact resistance increases, and Joule heating occurs at the transition.An increase in current-carrying capacity or a reduction in contact resistance, and therefore also in power dissipation, is achieved in this type of design almost exclusively by increasing the number of contact points. The choice of Ccr Lzn / eznz / q / YiAi spring material for spring connectors is always a compromise between electrical conductivity and mechanical properties, such as Young's modulus or relaxation. In addition to conducting electrical energy, modern vehicle wiring increasingly serves to conduct heat, primarily due to the high thermal conductivity of electrically conductive materials such as copper and aluminum. As a result, wiring is now often an essential component of thermal management in vehicles. A connection between two wires, between wires and electrical components, or between electrical components themselves—for example, between battery cell connectors or battery module connectors—a so-called floating conductor, therefore, also has the task of conducting heat in addition to electricity. However, connectors are not ideally suited for this purpose because such transitions in the wiring harness often generate unwanted additional heat due to Joule losses.Furthermore, heat transfer is hampered by the often thin spring components. Even worse, the low heat capacity of the thin springs, a design trait, can lead to rapid heating, which in the worst-case scenario can cause fires in the cables. Screw connectors are much better suited for heat transfer. In this case, comparatively large surfaces of two basic bodies are pressed together by a force generated by a wire. The large contact surface reduces ohmic resistance and increases thermal conductivity. Screw connectors also typically have a large thermal mass compared to plug connectors. Therefore, they heat up more slowly at high instantaneous currents than thin springs. In this way, they ensure a low risk of overheating due to the slow thermal behavior of the connection. Such a large thermal mass and high thermal conductivity are particularly necessary in the propulsion systems of electric vehicles, where high currents can occur during braking (through recuperation), acceleration, or high-current charging. However, the disadvantage of a screw connection is that, compared to a plug connection, it involves a more complex assembly step that takes longer and is more prone to errors. This is particularly problematic given the increasing automation of production in the electromobility sector. The longer time required to assemble threaded connections makes them less attractive for automated manufacturing. For example, in the production of high-current batteries, where a large number of battery cells and modules must be in contact with each other, the numerous threaded connections represent a considerable assembly effort.Furthermore, screw connectors can cause problems due to faulty threads or similar issues. Therefore, some screw connectors already use contact parts with two screw elements side by side to reduce susceptibility to failure / error rates. This leads to increased assembly effort. BRIEF DESCRIPTION OF THE INVENTION Therefore, the design of the material was based on the objective of combining the advantages of a screw connection with those of a plug connection. To this end, large surfaces must be pressed together with high normal forces to produce good electrical and thermal conductivity. Furthermore, the connector must have a high heat capacity to absorb a large amount of thermal energy without overheating. Another focus is on assembly, which must be fast, reproducible, and as easily automated as possible. This object is resolved by means of a connector according to claim 1 and a manufacturing method according to claim 22. ccr Lzn / eznz / q / YiAi The connector, according to the subject matter, comprises a first metallic part and a second metallic part. In particular, the metallic parts may comprise copper or a copper alloy and / or aluminum or an aluminum alloy. For example, high-strength aluminum alloys such as EN AW 6082 may be used. Other materials may also be used, such as other metals or alloys thereof, such as steel, silver, gold, lead, etc., or other conductors such as polymers, semiconductors, or the like. Combinations of conductors and non-conductors may also be used, in which the conductors are arranged at least on contact surfaces, which will be described later, and the non-conductors perform purely mechanical functions. Combinations of different materials, both better and worse conductors, such as different metals, for example, copper and steel, may also be combined.In this way, on the one hand, good conductivity can be achieved and, on the other hand, high mechanical stability at a reduced cost compared to a single-metal finish. The two metal parts can be made of the same material, specifically the same metal. This has the advantage of eliminating contact corrosion due to the different redox potentials of different metals. Another advantage is that there are no differences in coefficients of thermal expansion. Therefore, the two metal parts expand equally when heated, preventing thermal stress. It is also possible for both metal parts to be made of different materials and / or combinations of materials, particularly two different metals. For example, one metal part might be made of copper or a copper alloy, and the other metal part might be made of aluminum or an aluminum alloy. Therefore, aluminum wires, such as solid flat conductors, and copper wires, such as flexible stranded conductors, can each be connected to a metal part of the cable connector of only one type. This reduces or prevents contact corrosion between the wire and the connector. At least one of the metal parts may be made of solid material. This is advantageous for the component's heat capacity. It is also possible for at least one of the metal parts to comprise segments of flat sections. In this way, high stability can be achieved with low weight and material usage. Furthermore, the increased surface area can promote heat radiation and thus allow for greater maximum heat dissipation by the cable connector. In any case, the size of the metal parts can be adapted to the cable thickness and / or current intensity, and therefore to the expected heat generation and power loss. A larger size leads to a greater surface area over which heat can be radiated and transported by convection. Additionally, a larger volume leads to greater heat capacity. Connection terminals for conductors can be provided in one or both metal parts. These can be round, flat, or other shaped connection terminals. The terminal lugs can be formed for soldering the wires, for example, by friction welding, ultrasonic welding, resistance welding, laser welding, etc. The terminal lugs can be roughened, coated, or otherwise surface-treated. In addition, one or more holes can be provided in the terminal lugs. Connection terminals can also be configured as sleeves and / or cable terminals. These can be suitable for contacting and / or accommodating flat conductors, round conductors, solid conductors, and / or stranded conductors. Connection terminals are preferably made of the same material as the metal part to which they are attached. They can also be made of a different material. In order to define the relationships between surfaces, normal surfaces are used. First, a surface is a contiguous area on a three-dimensional body that can be divided into several segments. A surface does not need to be flat; it can be composed of segments with different spatial orientations. The orientation of a surface segment is characterized by its surface normal. A surface normal is a vector that is exactly perpendicular to the associated surface segment. The normals of a surface segment of a body point away from the body such that the vector lies outside the body. The length of the surface normal vector is irrelevant and is defined as normalized to a value, for example, 1 of a certain chosen unit of length. Two vectors are described as opposite to each other if their dot product is less than zero.It is possible, but not necessary, for the two vectors to be exactly antiparallel to each other. If the two vectors are perpendicular to each other, their dot product is exactly zero. The two metal parts rest against each other in specific areas. An interlocking member separates the two metal parts. The interlocking member moves each metal part in a respective locking direction. The respective locking direction can be represented by a vector. The locking directions of the two metal parts are opposite to each other (see above, the dot product less than zero) and, in particular, can be substantially antiparallel to each other. The locking member can be formed as a locking surface on each of the two opposing metal parts, which are separated by a gap. By inserting a third element, a locking member, between the two locking surfaces, the two metal parts can be separated. In this case, the locking member can be in the form of a parallelepiped, a cylinder, or otherwise; in particular, the locking member can be tapered along a spatial axis. Thus, the locking member can be wedge-shaped. The locking member is preferably inserted into the gap in an insertion direction that is oriented differently from the locking directions of the two metal parts. The insertion direction can be substantially perpendicular to the locking direction of at least one of the two metal parts.The locking member may be textured for improved grip, for example, by means of protrusions, grooves, corrugations, a rough coating, etc. Furthermore, at least one of the locking surfaces may have the corresponding shape ccr Lzn / rznz / q / YiAi. It is also possible that the locking member and / or at least one of the locking surfaces may be coated, for example, with non-conductive materials such as silicone, rubber, or plastic, which in particular can deform elastically and thus absorb mechanical stresses. In addition, the locking member and / or at least one of the locking surfaces may be coated with a conductive material such as nickel or tin, which may be softer than the other material of the locking member. The interlocking member can be manufactured, at least in part, from a material similar to or the same as one or both of the metal elements. This choice of material avoids differences in coefficients of thermal expansion and prevents contact corrosion. Alternatively, the interlocking member can be made of a different material than at least one of the metal elements, which may be conductive or non-conductive. The interlocking member can also be made of a solid material. In this case, it can be made of a material with low compressibility, such as solid copper or aluminum. It is also possible for the interlocking member to be made of an elastic material, such as plastic, rubber, silicone, etc., or combinations of materials, such as rubber-coated glass or ceramic.In this case, an interlocking member made of a solid material can, at least in sections, fit exactly into the space between the two locking surfaces, the width of which is determined by the other connector design as described below. It is also possible that the locking member is not made of a solid material, but rather has an elastic structure with resilient characteristics. For example, it may comprise metal stirrups. Elastic elements, such as stirrups, can absorb mechanical stresses such as deformation and flexibly fit into the space between the locking surfaces. No additional material is required between the elastic elements. However, it is also possible that the locking member comprises other components besides the elastic elements, such as a support filler, electrically conductive or non-conductive, which may be solid or elastic, etc. The locking member can be formed as a separate element, completely separable from the two metal parts. It can also be attached to one of the two metal parts in a guided manner. For example, a rail can slide along the locking element in substantially one direction. Alternatively, the locking member can be rotatably mounted on one of the metal parts and screwed in place. Since the contact area with an inwardly rotated locking member can be small compared to a press-fit locking member, in this case, surface roughening, for example, by grooving, is highly recommended. The advantage of a guided locking member is, firstly, that it cannot be lost if the connection is reopened. Furthermore, it can be advantageous in assembly if separate locking members do not need to be stored. The metal parts are in contact with each other in certain areas. Contact surfaces are provided for this purpose. Each of the two metal parts has a front contact surface located behind the locking member in the metal's locking direction. Each of the two metal parts also has a second rear contact surface located in front of the locking member in the locking direction. Thus, the locking member or components of the locking member, arranged on the respective metal part, are located between the two contact surfaces, rear and front, of the metal part. The rear contact surface is separated from the locking member by the respective locking direction of the metal part, and the front contact surface is separated from the locking member by the respective locking direction of the metal part.In this context, the term "locking member" refers to the portion of the locking member that forms part of the respective metal component. For example, this could be the locking surface of the respective metal component described above. ccr Lzn / eznz / q / YiAi In addition to the two contact surfaces, the front and the rear, each of the two metal parts also has two additional surfaces, the bearing surfaces. A first front bearing surface is separated from the locking member in the locking direction of the respective metal part. A second rear bearing surface is separated from the locking member against the locking direction of the respective metal part. The front bearing surface of each metal part is therefore on the same side of the locking member along the locking direction as the front contact surface. The rear contact surface and the rear bearing surface of the same metal part are located on the other respective side of the locking member. The front bearing surface may be located further from the locking member in the locking direction than the front contact surface.The front bearing surface may also be closer to the interlocking member than the front contact surface, at least in certain areas. The same applies to the rear bearing and contact surfaces. The front (rear) contact surface and the front (rear) bearing surface of at least one metal member may be directly fused together, so that an uninterrupted line can be drawn from the bearing surface to the contact surface. Alternatively, the front (rear) contact and bearing surfaces may be separated from each other. The two metal parts can have a substantially identical shape to each other. A bonded state of the two metal parts can now be defined. In this case, the front contact surface of the first metal part rests on the rear contact surface of the second metal part at least in some areas, and the rear contact surface of the first metal part rests on the front contact surface of the second metal part at least in some areas. Furthermore, the front support surface of the first metal part rests on the rear support surface of the second metal part at least in some areas, and the rear support surface of the first metal part rests on the front support surface of the second metal part at least in some areas. In this context, "support" means that the surfaces can exert a force on each other, either directly or indirectly.Preferably, mechanical and electrical contact is established between the contact surfaces and / or between the end faces by means of a support. Another element, such as a conductor or a non-conductor, may also be placed between the surfaces. In the case of support surfaces, such an intermediate layer may, for example, absorb mechanical stresses and / or facilitate the sliding of the metal parts against each other. In the case of contact surfaces, such an intermediate layer may be, for example, a soft conductive sheet that compensates for irregularities and establishes good contact. Furthermore, the intermediate elements mentioned as examples may be used on the other respective surfaces (support or contact surfaces). In any case, the large surface contact of the surfaces, particularly the contact surfaces of the two metal parts, is advantageous in achieving low ohmic resistance and good thermal conductivity. In the United States, the two metal parts may have a substantially closed outer surface, which may, for example, substantially describe a parallelepiped, a cylinder, a sphere, an ellipsoid, a wedge, or a similar shape. The tight fit of the two metal parts avoids unnecessary edges, thus reducing the risk of damaging adjacent wires or other components, particularly in tight harnesses. In the United States, the bearing surfaces of each metal part serve a purpose: to stop the movement of the other respective metal part in its locking direction. Thus, when the first metal part moves in its locking direction, at least one of its two bearing surfaces—preferably both the rear and front bearing surfaces—comes into contact with the bearing surfaces of the second metal part, either the front and / or the rear. To this end, the bearing surfaces of each of the two metal parts are oriented, at least in some areas, in the opposite direction to the locking direction of the other respective metal part.In this case, reference is made to the previous definition of “opposite direction,” which states that the dot product between the normal surfaces of the bearing surfaces of one metal part is negative with respect to the locking direction vector of the other respective metal part. “At least in some areas” means that at least a portion of the surface has a corresponding orientation. Since the surface need not consist of a single flat segment, it is conceivable that some portions of the adjacent surfaces do not oppose the locking direction of the other respective metal part, while others do. In particular, the areas of the bearing surface must be opposite to the locking direction of the other respective metal part, against which the other respective metal part also actually rests in the joined and / or locked state. For each pair of bearing surfaces, for example, the back of one metal part and the front of the other, only one of the two bearing surfaces may be oriented against the direction of movement of the other. The other respective bearing surface may also be formed as a local linear or point-like elevation, or in some other form. Multiple elevations are also conceivable. Furthermore, the two bearing surfaces of a pair may be flat and substantially parallel to each other in the locked state. As a second additional purpose, the bearing surfaces redirect the force emanating from the locking member at least partially in the direction of the contact surface. For this purpose, the respective front contact surface and the respective front bearing surface of a metal part are first defined as each "belonging" to the other surface, and the respective rear contact surface and the rear bearing surface of the same metal part are defined as "belonging" to each other. The redirection of the force is now achieved by the fact that each bearing surface is directed not only against the locking direction in certain areas, but also against areas of the respective associated contact surface. Consequently, the contact surface is also directed in areas opposite to the associated impact surface. In this way, the interlocking member exerts a force on the contact surfaces through the bearing surfaces, pressing them together with a normal force. Thus, the front contact surface of the first metal part is pressed against the rear contact surface of the second metal part. The rear contact surface of the first metal part is also pressed against the front contact surface of the second metal part. A large force is advantageous for ensuring good contact with low contact resistance. As described above, it is advantageous for both the metal parts and the interlocking member to have similar or equal coefficients of expansion, so that the normal force does not decrease over an expected temperature range of -40 °C to 150–180 °C due to differing coefficients of expansion. As described above, the surfaces—that is, both contact and impact surfaces—do not need to be perfectly flat and formed from a single flat segment, but can be formed from multiple segments oriented in different ways. In particular, the contact and / or bearing surfaces can have a relief, which may take the form of ridges and grooves along which one metal part can slide against the other. For example, these relief structures can be substantially constant along the respective locking direction, particularly if the locking direction of one metal part is exactly perpendicular to the normal surface of a relief contact surface. It is also possible for the contact and / or bearing surfaces to have a concave and / or convex shape.In an advantageous embodiment, the embossed structures of the two metal parts interlock, increasing the contact surface area compared to flat surfaces and guiding the metal parts against each other. Specifically, for example, the respective front contact surface may have concave cavities, and the respective rear contact surface may fit into these concave cavities with a convex shape. Similarly, the respective front contact surface may have convex cavities, and the respective rear contact surface may fit into these convex cavities with a concave shape. The same principle applies to the front and rear bearing surfaces. Of course, other surface textures, such as serrated, triangular, or toothed reliefs, are also possible. In a preferred embodiment, the contact surfaces of a first metal part are aligned parallel to the locking direction of the respective metal part and / or the other metal part, at least in certain areas. The same may apply to the second metal part. The metal parts can then slide against each other on the contact surfaces. Furthermore, the contact surfaces of a metal part, front and rear, can be substantially parallel to each other, at least in certain areas, but also entirely. Additionally, the contact surfaces of both metal parts can be all four parallel to each other, at least in certain areas, but also entirely. The same applies to adjacent surfaces, both for one metal part and for both metal parts equally. Furthermore, the contact surfaces of a pair of supported contact surfaces, formed by one contact surface from each of the two metal parts, can be substantially parallel to each other. This can apply to both pairs of contact surfaces of the cable connector. The same can apply to the support surfaces. In a preferred embodiment, both the locking directions of both metal parts and the normal surfaces of both contact surfaces and both bearing surfaces of both metal parts run, at least in some areas, substantially parallel to a common plane or to each other. ccr Lzn / eznz / q / YiAi The bearing surfaces and / or contact surfaces can be coated, at least in some areas. In particular, they can be provided with a nickel and / or tin coating, which can be softer than the main material of the metal parts and thus provide better contact. The bearing surfaces and / or contact surfaces can also be surface treated in other ways, for example, by polishing them and making them particularly flat. Other designs are conceivable as an alternative to the locking member, comprising locking surfaces and a retractable locking member. For example, a screw mechanism is conceivable that is anchored in a thread on one of the two metal parts and can be drawn from this part against the other metal part to a locking surface. Furthermore, both metal parts can have such screw elements that can extend against each other. Spring elements or spring-loaded elements firmly attached to the metal part are conceivable, which clamp together when the two metal parts are locked together, thereby exerting a permanent force and maintaining contact between the metal parts in the locked state. To provide protection against moisture and other environmental influences, a protective coating may be provided for the cable connector. This coating may consist of a material such as plastic, silicone, ceramic, rubber, or glass over the metal parts. This coating is preferably applied to the surfaces of the metal parts that are not contact and / or impact surfaces. The coating may also be applied to the area of ​​the locking member, but the surface of the metal parts in this area may also be excluded. The coating may extend laterally beyond the bearing and contact surfaces to achieve a good seal of the cable connector in the assembled state, ensuring that no gaps remain through which water and other chemicals can penetrate.Furthermore, the protruding coating edges can be arranged as a groove on one metal part and a flange on the other metal part so that they interlock when the metal parts are joined. Additionally, the coating edges of both metal parts can have the same shape, such as flanges, thickenings, grooves, etc. It may be advantageous to select a coating for one metal part that is harder than the coating for the other, so that the edge of the coating on the first metal part can press against the coating on the other, thus achieving a better sealing effect. It is possible that the interlocking member may leave an opening in the cable connector, for example, if the interlocking member is countersunk between the locking surfaces. However, to achieve insulation against moisture and other environmental influences, a cover can be provided to protect the remaining opening. Furthermore, the interlocking member itself can close the opening through which the two metal elements pass. For this purpose, the wedge may have, for example, an insulating cap. In particular, closing the opening can create protection against contact, especially against fingers (IPxxB standard) or wires (IPxxD standard), and / or seal the opening watertight and / or airtight. A housing can also be installed around the entire cable connector, which is placed around it in the assembled state. The housing can be made of silicone, rubber, or preferably harder materials such as plastic or even ceramic. Furthermore, two or more housing components can be placed separately around and / or attached to both metal parts, and these can also be sealed together in the assembled state. Press-fit elements and / or a circumferential seal made of a softer material than the housing, such as silicone or rubber, can ensure a permanent seal. In a further embodiment, a metal part may have, in addition to the first two contact surfaces, bearing surfaces, and parts of a first locking member, two additional contact surfaces, two additional bearing surfaces, and parts of an additional locking member. The metal part thus formed may be connected to one, two, or more additional metal parts to provide, for example, a Y-connection. Furthermore, a metal part may have additional connection surfaces and locking members and allow for a 4, 5, and 6 coupling or the connection of additional elements and / or cables. In particular, metal parts can be manufactured, for example, by die casting, investment casting, or an extrusion process. These processes allow for a particularly fine, flat, and uniform surface. However, it is also possible to choose other processes, which can be combined with a subsequent surface treatment. BRIEF DESCRIPTION OF THE FIGURES The subject matter is explained in greater detail below by means of figures showing embodiments of the invention, in which: Figures 1a-1b show embodiments of the two metal parts of the present cable connector. Figure 2 shows embodiments of a metallic object part with normal surfaces drawn. Figures 3a-3g show an embodiment of two representative metal parts hooked together in a plan view. Figures 4a-4b show an embodiment of the present cable connector in isometric view. Figures 5a-5c show embodiments of the support surfaces of the present cable connector. Figures 6a-6f show embodiments of the locking member of the present cable connector. Figures 7a-7e show embodiments of the contours of the support and contact surfaces of the present cable connector. Figures 8a-8d show embodiments of an insulated wire connector in question. Figures 9a-9b show embodiments of a cable connector with a metallic part provided for multiple contacts. Figures 10a-10d show embodiments of connection terminals of the cable connector in question. DETAILED DESCRIPTION OF THE INVENTION The present cable connector 1 is formed by a first metal part 20 and a second metal part 40, which are shown in Figure 1a. The first metal part 20 has a front support surface 28, a rear support surface 22, a front contact surface 26 and a rear contact surface 24. Similarly, a second metal part 40 is provided. This, in turn, has a front support surface 48, a rear support surface 42, a front contact surface 46 and a rear contact surface 44. It can be advantageous to match the two metal parts 20, 40 in their external dimensions, particularly their thickness, so that few edges protrude after joining. In particular, it is possible for the two metal parts to have a substantially identical shape. Figure 1b shows the two metal parts 20, 40 in the joined state. In this case, the front bearing surface 28 of the first metal part 20 rests on the rear bearing surface 42 of the second metal part 40, and the rear bearing surface 22 of the first metal part 20 rests on the front bearing surface 48 of the second metal part 40. Furthermore, the rear contact surface 24 of the first metal part 20 rests on the front contact surface 46 of the second metal part 40, and the front contact surface 26 of the first metal part 20 rests on the rear contact surface 44 of the second metal part 40, resulting in substantially a parallelepiped. The fact that the surfaces support each other can be understood to mean that they exert a force on each other, at least in certain areas. They can also support each other indirectly through one or more elements ccr Lzn / rznz / q / YiAi arranged between the contact surfaces. The two metal parts 20, 40 are offset from each other by an interlocking member 60. In the embodiment shown, a wedge 66 is used as the interlocking member, inserted between two locking surfaces 62, 64. A first locking surface 62 is located on the first metal part 20, and a second locking surface 64 is located on the second metal part 40. When the interlocking member 66 is pushed in, it contacts both locking surfaces 62 and 64, separating them and thus the metal parts 20, 40. Preferably, the interlocking member 66 can be inserted into the space with a precise fit to create an interference fit between the locking surfaces 62, 64. The locking member 66 can be pressed into the space between the locking surfaces 62, 64 with a predetermined pressure or force. A final position can be defined for the locking member 66 in which the two metal parts 20, 40 are firmly locked and the locking member 66 can only be moved forcefully due to friction on the locking surfaces 62, 64. In this state, the locking member 66 can either protrude beyond the surface of the metal parts 40, 60, flush with at least one of them, or form a cavity in the cable connector 1. The first metal part 20 is moved by the locking member 60 in a first locking direction 50, and the second metal part 40 is moved in a second locking direction 52. The locking directions 50, 52 are different from each other, in particular opposite to each other (scalar product < 0) and, in particular, they can be antiparallel to each other. With reference to Figure 2, it should be noted that the assessment of whether two vectors are perpendicular to each other can be carried out by displacing the vectors so that their starting points are identical (see right side of Figure 2). For the case shown in Figure 2, it is obvious that the surface normal vectors 23, 29 of the bearing surfaces 22 and 28 of the first connecting part 20 are opposite both to the locking direction 52 ccr Lzn / eznz / q / YiAi of the second metal part 40 and to the surface normal vectors 25, 27 of the contact surfaces 24 and 26. In one respect, this causes the first metal part 20 to support the second metal part 40 in the locking direction, since the bearing surfaces 42 and 48 of the second metal part 40 bear against the bearing surfaces 22, 28 of the first metal part 20, which bear against the locking direction 52 of the second metal part 40. This applies in exactly the opposite way to the first metal part 20, which is prevented from further movement in its locking direction 50 by the bearing surfaces 42, 48 of the second metal part 40. Furthermore, the orientation of the normal bearing surfaces 23, 29 in opposition to the associated normal contact surfaces 25, 27 causes the second metal part 40, which is moved by the locking member 60 against the bearing surfaces 22, 28, to deflect in the direction of the contact surfaces 24, 26. The second metal part 40 now rests against these contact surfaces 24, 26 with their respective contact surfaces 46, 44, so that it is held in at least one force-locking and form-locking manner. Figures 3a–3g show various possible orientations of the contact surfaces 24, 46, 26, 44 and the bearing surfaces 28, 42, 22, 48 of the two metal parts 20, 40. A top view of the cable connector 1 in question is shown. The contact and bearing surfaces 24, 46, 26, 44 in this case can be substantially flat surfaces with a single orientation perpendicular to the drawing plane. They can also be curved, twisted, or otherwise deformed. It is intended that at least one segment of each surface be oriented substantially perpendicular to the drawing plane for the following reasons, so that the seam lines in Figures 3a–3g reveal the area-by-area orientation of the surfaces.In the embodiments shown in Figures 3a-3c, the interlocking directions 50, 52 of the two metal parts 20, 40 are parallel to the contact surfaces 24, 26, 44, 46, which are aligned ccr Lzn / eznz / q / YiAi parallel to each other in the joined state. For a more detailed explanation of the surface orientations, see Figures 3a-3g, which show the normal surfaces 23 (perpendicular to the rear bearing surface 22), 25 (perpendicular to the rear contact surface 24), 27 (perpendicular to the front contact surface 26), 29 (perpendicular to the front bearing surface 28) for the first metal part 20. It can be seen that in all the embodiment examples of Figures 3a-3c, the support surfaces 22, 28, 42, 48 are directed in the opposite direction to the locking direction of the other respective metal part (scalar product between the normal surface vectors 23, 25, 27, 29 and the locking direction vector 50, 52 < 0). It can also be seen that the surface normal vectors 23, 29 of the support surfaces 22, 28 are directed in the opposite direction to their respective associated contact surface. Figure 3d shows a design in which the contact surfaces 24, 26, 44, and 46 are curved in plan view. They can also be curved to such an extent that their area normals no longer oppose the normals of the associated bearing surfaces 22, 28, 42, and 48. It is sufficient if the normals of the contact surfaces 24, 26, 44, and 46 are regionally opposed to the normals of the respective associated bearing surfaces 22, 28, 42, and 48. In the embodiments of Figures 3a-3d, the bearing surfaces 22, 28, 42, and 48 are located mostly farther from the locking member 60 than the respective associated contact surfaces 24, 26, 44, and 46 are located along their entire extent. However, the bearing surfaces 22, 28, 42, and 48 can also be located closer to the locking member 60 than at least some regions of the associated contact surfaces 24, 26, 44, and 46, as shown in Figure 3e.The bearing and contact surfaces 24, 26, 44, 46, 22, 28, 42, 48 ccr Lzn / rznz / q / YiAi generally need not be formed from a single flat segment, but may include segments of different orientations. An exemplary embodiment with such surfaces is shown in Figure 3f. In this case, the bearing surfaces 22, 48, 26, and 42 are first separated into subregions (22a, 22b, 22c, as well as 48a, 48b, 48c and 28a, 28b, 42a, 42b), each of which has an orientation according to the invention. The horizontal bearing surface regions in the figure have a different orientation. In general, the bearing surfaces comprise these horizontal subregions and the aligned subregions according to the invention (22a, 22b, 22c, as well as 48a, 48b, 48c and 28a, 28b, 42a, 42b). Bearing surface 28 has been provided with protrusions. The protrusions 28a, 28b themselves may also be considered as bearing surface 28.The orientation of its surface is irrelevant to the function of the invention. However, at least small segments of the protrusion will be oriented in the opposite direction to both the locking direction 52 of the second metal member 40 and the normal surface of the associated contact surface 26. The orientation of the bearing surface 42, more specifically its partial regions 42a, 42b, already causes the first metal part 20 with its contact surface 26 to be pressed against the contact surface 44 of the second metal part 40. In this case, it is clear that the opposite alignment in areas of the two bearing surfaces (22, 48) and (28, 42) is sufficient to press the associated contact surfaces (24, 46) and (26, 44) together by means of the locking member 60. Figure 3g shows another related embodiment in which the bearing surfaces 22, 48 and 28, 42 are divided into three subregions, each of which has a substantially constant orientation. The horizontally aligned subregions (substantially vertical normal surfaces) in this case are aligned according to the invention. The vertically aligned partial areas (essentially horizontal normal surfaces) alone would not achieve the desired interlocking. In this case, too, the term “bearing surface” may refer either to the horizontally aligned subarea in each instance, or to the composite surface consisting of two vertically aligned subareas and one horizontally aligned subarea in each instance. Figures 4a-4b show two different exemplary designs of the metal parts 20, 40. In Figure 4a, both metal parts 20, 40 are formed from several flat segments. The contact surfaces 24, 26, 44, 46 and the bearing surfaces 22, 28, 42, 48 are formed from respective flat segments directed substantially parallel to the respective bearing or contact surface. Perpendicular flat elements are provided to increase mechanical stability. These are optional. One advantage of this design is the reduction in material requirements, and another is the increase in the surrounding surface area over which heat can be radiated and dissipated elsewhere, such as by convection. Another design, shown in Figure 4b, resembles a cylinder. A cylindrical shape facilitates the integration of cable connector 1 into cable harnesses. This is because, for example, the connector can be roughly adapted to the diameters of the cables, particularly for cables with round diameters. This avoids thickening along the cable harness in the area of ​​cable connector 1. Furthermore, thanks to the lack of edges, adjacent components, particularly cables, are less likely to be damaged. Figures 5a-5c elaborate in further detail on the embodiment of Figure 3g. One of the bearing surfaces of two bearing surfaces in contact with each other may be in the form of one or more point-like, linear, or other shaped elevations instead of a surface. The protrusion may be flattened and have an end face oriented substantially parallel to the bearing surface when locked. However, it may also be rounded. A rounded shape is shown in Figure 5a. If the elevation is rounded, only a very small surface segment of the bearing surface 42 aligns against the locking direction 50 of the first metal part 20 and the normal surface of the contact surface ccr Lzn / eznz / q / YiAi 44. The orientation of the other respective bearing surface, which is formed as a surface, is sufficient to guide the two contact surfaces associated with the respective bearing surfaces to each other from the force emanating from the locking member 60. The elevations of a bearing surface may, for example, substantially describe a line as in Figure 5b. In this case, the elevation is not rounded as in Figure 5a, but has a flattened end face. However, a rounded shape is the best possibility. Several such mutually parallel or mutually inclined linear elevations are also possible. Alternatively, point-like elevations as in Figure 5c are conceivable. In this case, single or multiple elevations distributed in an orderly or disordered manner over the bearing surface are also conceivable.Furthermore, at least one bearing surface may be alternately heavily roughened, resulting in an irregularly shaped surface structure with elevations and depressions, which partially contact and / or are pressed against the opposite bearing surface of the other respective metal part in certain areas and / or penetrate the opposite bearing surface when the present cable connector 1 is locked. Figures 6a-6f show possible embodiments of interlocking members 60, in addition to the wedge 66 described in Figure 1a, with locking surfaces 62, 64. In particular, some guided embodiments of the locking members 66 are disclosed. The guide 67 may have the characteristic that the locking member 66 can only be moved in one direction. Furthermore, the guide 67 can connect the locking member 66 to at least one of the metal members 20, 40 in such a way as to prevent its loss. This has the advantage that, for the assembly of the present cable connector 1, it is only necessary to handle two separate elements, namely the two metal parts 20, 40. It is not necessary to keep any locking member 66 in storage on a processing machine, etc., because when the cable connector 1 is opened, the locking member 66 is not in danger of being lost. ccr Lzn / eznz / q / YiAi In Figure 6a, a wedge is described as an interlocking member 66 that can be moved along a guide 67. This guide 67 may comprise a substantially linear rail or protrusion on the locking surface 62, which is surrounded by a substantially linear groove or recess in the locking member 66. In addition, the guide may be arranged as a recess in the locking surface 62 of the metal part 20 (or the locking surface 64 of the metal part 40), and the lift may be arranged on the interlocking member 66. Figure 6b shows another example of an interlocking member 60 with guide 67. In this case, the locking member 66 can rotate around a guide 67 shaped as a swivel bearing. Rotating the locking member 66 from the upper position to the lower position shown in Figure 6b achieves the locking of cable connector 1. In this case, the rounded shape of the locking member 66 is advantageous, allowing it to be moved fully in space to the final position shown at the bottom of Figure 6b. In the two configurations shown, but also in other interlocking member configurations, it can be useful to increase the friction between the interlocking member 66 and the locking surfaces 62, 64. This can be done by roughening the surface, sandblasting, etching, and other processes, or also by deliberate relief, for example in casting, whereby grooves, protrusions, waves, etc., are produced, which can increase the friction between the interlocking member 66 and the locking surfaces 62, 64. Figure 6c shows roughened surfaces as an example. The alternative locking members 60 are shown in Figures 6d-6f. In Figure 6d, the locking member 60 comprises a screw guided in a thread of a first metal part 20, which can be rotated against the locking surface 64 of the second metal part 40. In this case, the locking member 66 is the screw. Figure 6e shows a spring element as an interlocking member 66, which is fixed or movably attached to the locking surface 62 of the first metal part 20 and is pressed together when the two metal parts 20, 40 are brought together so that the restoring force of the spring element separates the two metal parts 20, 40. Analogous to Figure 6e, Figure 6f shows a different spring element. The spring element in Figure 6d has the advantage that lateral insertion does not significantly deflect the spring downward and that the spring can press the metal part in the locking direction even after insertion. The spring in Figure 6f may require additional guidance in the spring direction. The spring element as an interlocking member 66 generally has the advantage that the two metal parts 20, 40 can be brought together and locked immediately.The disadvantage, however, is the significantly reduced force exerted by the locking member 60 compared to, for example, a press-fit metal wedge under pressure. Therefore, the normal force on the bearing and impact surfaces is reduced, and the contact can become more resistant. As discussed earlier, the contact surfaces 24, 26, 44, 46, the bearing surfaces 22, 28, 42, 48, and the locking surfaces 62, 64 need not be flat with a single orientation but can have areas of different orientations. Some examples of such surface shapes are shown in Figures 7a-7e. In this case, a relief is shown as would be visualized when cutting the two metal parts 20, 40. It is advantageous if the surfaces of the metal parts 20, 40 can slide along each other in a preferred direction. This can be ensured for the contact surfaces if the profile is constant along a direction perpendicular to the locking direction of at least one of the metal parts. For example, grooves can be formed in the metal along this direction.For bearing surfaces 22, 28, 42, and 48, a consistent relief in the direction of the corresponding contact surface should be useful so that the metal part slides along this profile toward the contact surface. Figure 7a shows an advantageous profile course described with an exemplary angle profile ccr Lzn / rznz / q / YiAi. Furthermore, it is beneficial if the metal parts 20 and 40 interlock at the contact and support surfaces. This allows the metal parts 20 and 40 to be guided securely. They also remain more firmly joined in the locked position, and the contact area is increased compared to flat contact and support surfaces. The described profiling is particularly advantageous for the contact surfaces. Figure 7b shows a first wave-like profile, while Figure 7c shows a concave profile of a first surface and a complementary convex profile of a second surface. Figure 7d shows another embodiment of interlocking surfaces. To improve contact between the bearing and contact surfaces, they can be coated, in particular, with softer metals such as nickel or tin. Other metals such as gold or other conductive materials are also possible. Advantageously, a coating is applied only to the contact region between the bearing and contact surfaces; see coatings 70, 72 in Figure 7e. The wire connector 1 described so far generally still has an unprotected outer metal surface. This has the disadvantage that it can come into electrical and mechanical contact with other conductors, and there is also a risk of corrosion or other damage due to environmental influences. To eliminate these risks, it is advantageous to insulate the wire connector 1 from the outside. This can be done by using a housing that is placed around the wire connector 1 after connection and locking. Figure 8a shows another advantageous embodiment of environmental isolation. In this case, the metal parts 20, 40 are coated with an insulating layer 80 on at least portions of the outer surfaces that are not contact surfaces, bearing surfaces, interlocking surfaces, or other outer surfaces that are not to be insulated. This layer is preferably non-conductive and can be made of plastic, silicone, rubber, but also ceramic, glass, etc. ccr Lzn / eznz / q / YiAi To allow complete isolation of the metal parts 20, 40 of the cable connector 1 in the locked state, a cover 82 can close the opening in the area of ​​the locking member 60 after locking. The cover 82 can also be part of the locking member 66, which may have, for example, an insulating closure that locks the opening when pushed inward. Furthermore, the cover can be formed as part of the housing. The wedge head can also have an insulating coating. Additionally, the wedge can be formed as part of the housing. In the transition zones between the insulating layer 80 and the bearing and / or contact surfaces, which must be in direct electrical and mechanical contact with each other, there is a greater risk of moisture penetration. To prevent this, the insulating layer 80 can protrude over the surfaces as shown in Figures 8c-8d. A groove 84 in the protrusion of the insulating layer 80 on one metal part and a corresponding protrusion 86 that mates with the groove in the insulating layer 80 of the other metal part can enable greater insulation performance at the joint of the two metal parts 20, 40. In addition, a plurality of grooves 84 and flanges 86, arranged side by side and mated to each other, can be provided to enhance the sealing effect. Furthermore, as shown in Figure 8d, an insulating layer 80a, 80b of a first metal part 20 can be softer than the insulating layer 80c, 80d of the second metal part 40. As a result of the fact that the protrusion of the harder insulating layer 80c, 80d can be pressed into the softer insulating layer 80a, 80b, the insulation becomes particularly airtight. The cable connectors 1 described so far are intended for connecting two cables or other components. It is also possible to extend the connection concept to multiple cables. Figures 9a-9b show an example of a cable connector 1 in which the second metal member 40 includes a plurality of mating portions for cable connectors 1, each comprising a front bearing surface 48, a front contact surface 46, a rear contact surface 44, and a rear bearing surface 42. At least portions of locking members 60 are also provided. Figure 9a shows a star-shaped design, and Figure 9b shows a side-by-side design. Connections are needed to attach cable connector 1 to the wires. For example, Figures 10a-10d show some embodiments of 90-degree cable connection terminals. Figure 10a depicts a tab with a hole for this purpose. This can be used for screwed or riveted connections. Figure 10b shows a flat 90-degree terminal without a hole, for example, for press-fit or soldered connections. Figure 10c shows a round 90-degree terminal, which can be formed from a solid material. In this case, for example, the wires can be soldered, particularly by friction welding, ultrasonic welding, and / or laser welding. A hollow design, such as a 90-degree sleeve as shown in Figure 10d, is also conceivable. This sleeve can accommodate wires or other elements, such as a cable terminal. The 90-degree sleeve can also have a round cross-section.

Claims

1. A cable connector for motor vehicles comprising: - a first metal part, - a second metal part supported on the first metal part, - an interlocking member separating the two metal parts in respective locking directions, wherein: - the interlocking member has a first locking surface on the first metal part and a second locking surface on the second metal part, which are oriented in opposite directions and separated from each other, and - furthermore has a locking portion, which is located between the two locking surfaces and separates them,- wherein each of the two metal parts has a respective front bearing surface and an associated front contact surface away from the locking member in the locking direction of the respective metal part and a respective rear bearing surface and an associated rear contact surface away from the locking member opposite the locking direction of the respective metal part, - wherein, in a locked state of the cable connector, the front bearing surface of each of the two metal parts rests on the rear bearing surface of the other respective metal part,and the front contact surface of each of the two metal parts rests on the contact surface of the other respective metal part; characterized in that: - the normal surfaces of the front and rear support surfaces of one respective metal part run at least in regions opposite to the locking direction of the other respective metal part, and - for each of the two metal parts, the normal surfaces of the front support surfaces run at least in regions opposite to the normal surface of at least part of the associated front contact surfaces, and - for each of the two metal parts, the normal surfaces of the rear support surfaces run at least in regions opposite to the normal surface of at least part of the associated rear contact surfaces.

2. The motor vehicle cable connector according to claim 1, further characterized in that the front contact surface of at least one of the two metal parts is substantially in direct contact with the rear contact surface of the respective other metal part over the width perpendicular to the locking direction, at least in regions, and the surface profiles of the two contact surfaces are substantially constant along the locking direction of at least one of the two metal parts.

3. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the locking member comprises a first locking surface on the first metal part and a second locking surface on the second metal part, opposite each other and separated by a gap, and a locking wedge rests on both locking surfaces, such that the locking wedge pushes the two separated metal parts in their respective locking directions.

4. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the two metal parts have a substantially identical shape to each other.

5. The motor vehicle cable connector according to claim 1, further characterized in that the normal areas of the front and rear bearing surfaces and the front and rear contact surfaces of both metal parts and the locking directions of both metal parts are substantially parallel to a common plane. ccr Lzn / rznz / q / YiAi 6. The motor vehicle cable connector according to claim 1 or 2, further characterized in that the normal surfaces of the front and / or rear contact surfaces of at least one of the two metal parts are directed substantially in the same direction, at least in certain regions.

7. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the normal surfaces of the front and rear contact surfaces of at least one of the two metal parts are directed substantially in the same direction, at least in some areas.

8. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the locking direction of the first metal part is substantially opposite to the locking direction of the second metal part, in particular in that the locking directions of the two metal parts are antiparallel to each other.

9. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the front bearing surface of at least one of the two metal parts has at least a partially concave shape and / or the rear bearing surface of the other respective metal part has at least a partially convex shape, or the front bearing surface of at least one of the two metal parts has at least a partially convex shape and / or the rear bearing surface of the other respective metal part has at least a partially concave shape.

10. The cable connector for motor vehicles according to any of the preceding claims, further characterized in that the front support surface of one of the two metal parts has local elevations, in particular point or linear elevations.

11. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the front contact surface of at least one of the two metal parts ccr Lzn / rznz / q / YiAi has at least a partially concave shape and the rear contact surface of the respective other metal part has at least a partially convex shape, or in that the front contact surface of at least one of the two metal parts has at least a partially convex shape and the rear contact surface of the respective other metal part has at least a partially concave shape.

12. The motor vehicle cable connector according to any of the preceding claims, further characterized in that at least one of the bearing surfaces or contact surfaces of at least one metal part has an electrically conductive coating, in particular a nickel, silver, gold or copper coating.

13. The motor vehicle cable connector according to any of the preceding claims, further characterized in that at least one bearing surface of at least one metal part bears indirectly against the bearing surface of the other metal part, and a conductor or non-conductor is disposed between the bearing surfaces and / or at least one contact surface of at least one metal part bears indirectly against a contact surface of the other metal part and a conductor is disposed between the contact surfaces.

14. The motor vehicle cable connector according to any of the preceding claims, further characterized in that at least one of the two metal parts is coated with an insulating layer, in particular a non-conductive one, on at least one surface that is not a support or contact surface.

15. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the insulating layer of at least one of the two metal parts protrudes from at least one support and / or contact surface and / or in that the insulating layer of the first metal part is coupled in a bonded state with the insulating layer of the second metal part, in particular in that the insulating layers of the two metal parts are coupled together in a watertight manner at least sectionally or circumferentially.

16. The motor vehicle cable connector according to any of the preceding claims, further characterized in that a cover covers the locking member in the locked state, in particular in that the cover is a contact protection for the cable connector and / or makes it watertight with respect to the outside.

17. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the locking member is a screw element, a clamping element, a spring element and / or a wedge.

18. The motor vehicle cable connector according to any of the preceding claims, further characterized in that at least one of the metal parts has a connection support, in particular a hole, a connection tab, a plug, a socket, a thread, a clamp and / or a welding surface.

19. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the first metal part is made of a first metallic material and the second metal part is made of a second metallic material, the first metallic material being different from the second metallic material or the first metallic material coinciding with the second metallic material.

20. The motor vehicle cable connector according to any of the preceding claims, further characterized in that at least one of the metal parts is at least partially shaped as a flat part and / or at least one of the metal parts is at least partially shaped as a solid material.

21. The motor vehicle cable connector according to any of the preceding claims, further characterized in that the two metal parts substantially complement each other in the locked state to form a parallelepiped, a cylinder, a sphere, an ellipsoid or a wedge.

22. The motor vehicle cable connector according to any of the preceding claims, further characterized in that at least the first metal part has at least two additional contact surfaces and two additional support surfaces into which an additional metal part can fit, and at least a second locking member locks the first metal part to the second metal part.

23. A method for manufacturing a cable connector according to any of the preceding claims, characterized in that at least one of the two metal parts and / or an interlocking member is manufactured by die casting, investment casting and / or an extrusion process.

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